BoardConverting Serving the North American Corrugated and Folding Carton Industries for 38 years July 18, 2022 VOL. 38, NO. 29
Saica Pack: Open For Business In The U.S. BY DAN BRUNTON
Rusken Packaging Expands Footprint With TN Acquisition Cullman, Alabama based Rusken Packag- ing has announced the acquisition of a small sheet plant in Knoxville, Tennessee. This ac- quisition is effective as of July 1, 2022. “It gives me great pleasure to announce that we now have manufacturing capability in Knoxville, Tennesse,” said Randy Whiteak- er, Rusken COO. “As you may know, we have had assembly and warehousing in Knoxville for some time. With the acquisition of a small sheet plant, we have now added a second lo- cation and are working toward a full manufac- turing production schedule in the near future.” Rusken’s growth in East Tennessee will be led by Rusken’s Susan Brackett as Knoxville Site Manager and Jason Warner as Oper- ations Manager. This acquisition is part of a strategic focus to expand Rusken’s footprint throughout the Southeast, further growing its existing capabilities and customer base in the Knoxville and East Tennessee market. Rusken operates corrugated facilities and sheet plants in Cullman, AL; Heflin, AL; Lu- verne, AL; Jackson, TN; Clarksville, TN; Knox- ville, TN; Charlotte, NC; Cowpens, SC; Atlanta, GA; Conyers, GA; Harrisburg, AR; New Orle- ans, LA; Jackson, MS; and Tupelo, MS.
Saica Pack, the third largest European producer of recycled paper for corrugated board, has officially expanded into the U.S. market, starting up its first box plant in April. Located in Hamilton, Ohio, about 20 miles north of Cincinnati, the 360,000-square-foot greenfield plant is a mod- el of efficiency, exemplifying European innovation in every detail.
The plant is in the process of building volume, courting a list of high profile customers, and is currently operating one shift with 32 employ- ees. The goal is to have 120 employees by the end of 2023 operating three shifts. The production capacity target is 1,500,000 MSF (140m sqm) per year of corrugated board, which Gonzalo Aragüés, Industrial Projects Director, says will be achieved by 2029. The projected target for this year is 265,000 MSF (25m sqm). Customers are primarily consumer goods companies in the logistics and food and beverage markets. The U.S. plant also provides corrugat- ed sheets to local sheet plants. The percentage mix of shipped boxes versus sheets is 50/50 with the goal of changing that to 80 percent boxes and 20 percent sheets. Box styles are mostly single and two-col- or RSCs and trays. About 10 percent of finished goods is warehoused on-site. Focus On Automation The modern two-story plant is expansive. The reception entrance, administrative offices and training and conference centers are inviting CONTINUED ON PAGE 22 Gonzalo Aragüés, Industrial Projects Director, left, and Akin Burak Önder, GM, at Saica Pack’s greenfield plant in Hamilton, Ohio.
WHAT’S INSIDE
6 x x 8 x x 12 x x 26 x x 4 2022 Innovator Of The Year Award Competition Is Open 6 TAPPI/AICC Opens Registration For Corrugated Week 2022 10 ICG Names Clearwater Paper Its 2021 Supplier Of The Year 12 PPC Celebrates Inaugural PPC Week In Springfield, MA
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INNOVATOR of the YEAR
AVERAGE CONTAINERBOARD PRICES The average prices reported are tabulated from prices PAID by various sources throughout the United States the week previous to issue. Prices in some areas of the country may be higher or lower than the tabulated average. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser.
Tools and tooling – Education or employee incentive programs – Employee retention programs – Efficiency, productivity and safety innovations , and more. Share your innovative ideas! Boxmakers! Entry deadline - Friday, August 19, 2022 Open to all AICC Boxmaker members It’s easy to enter!
REGION E. Coast Midwest Southeast Southwest
42# Kraft liner
26# Semi-Chem. Medium
$1005.00-1010.00 $1020.00-1030.00 $1020.00-1030.00 $1020.00-1030.00 $1050.00-1060.00 $1023.00-1032.00
Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.
$940.00-990.00 $955.00-975.00 $955.00-975.00 $955.00-975.00 $975.00-995.00 $958.00-978.00
West Coast U.S. Average
SHEET PRICES BY REGION (AVERAGE) Per 1MSF, local delivery included, 50MSF single item order, truckload delivery. Sheets
E. Coast Midwest South-SW S. CA N.CA/WA-OR US Aver.
200# 275#
$62.26
$72.05
$62.69 $82.80
$85.35 119.54
$73.13 101.29
97.32
99.89
90.86
113.65
OYSTER UP-CHARGE 8.34
8.34
8.34
8.34
8.34
8.34
275# DBL-WALL 350# DBL-WALL
107.46 118.45
114.69 129.32
116.54 137.25 117.82 145.56
141.08 148.46
122.76 131.80
CANADIAN SHEET PRICES (AVERAGE) In Canadian Dollars, per 1MSF, local delivery included, under 50MSF single item order, truckload delivery. 200# 275# Oyster UC 275#DW 350#DW $78.56 $99.18 $9.00 $96.32 $105.83 CANADIAN LINERBOARD & MEDIUM The average prices reported are tabulated from prices PAID by various sources throughout Canada. Prices may be higher or lower in various areas of the country. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser. Prices are Canadian $ and per metric ton.
Visit aiccbox.org/invboxmaker or scan this code for details!
42# Kraft Liner 26#
Semi-Chem Medium
East West
$970.00
$960.00 $995.00
$1,015.00
T HE I NDEPENDENT P ACKAGING A SSOCIATION
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2022 Innovator Of The Year Award Competition Is Open
Core Competency
AICC, The Independent Packaging Association, and Board Converting News are accepting submissions for the 2022 Innovator of the Year Competition. This year’s category is open to AICC General Members (box makers) to showcase innovations developed since September 2017. The Innovator of the Year Competition is a video based competition. Winners will be selected by member vote at the AICC/TAPPI 2022 Corrugated Week Conference in San Antonio, Texas, during the general session on Tues- day, September 20, 2022. The winners will be announced on Wednesday, September 21, 2022, during the general session. The Innovator of the Year Competition provides an outlet for AICC’s boxmaker members to showcase their innovations that increase plant productivity, improve plant efficiency, enhance the workforce’s skill, safety and/or well-being or serves as the solution to a specific produc- tion or management problem. Previous winners include: Bay Cities in 2017, President Container Group in 2013, and Jellco Container Inc. in 2009. Competition entry brochure and entry form is available at www.AICCbox.org/innovator . Questions can be direct- ed to Cindy Huber, AICC Director of Conventions & Meet- ings, at chuber@aiccbox.org or (703) 836-2422.
BloApCo Floor Shredders easily handle Cores and Sheet Waste
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© Blower Application Company, Inc., Germantown, WI 2020
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TAPPI/AICC Opens Registration For Corrugated Week 2022
• FISCOTEC Meeting • Multiple Exhibit Hall Receptions • TAPPI Young Professionals Reception • AICC Emerging Leaders Reception • Tuesday Evening Event at Tejas Rodeo • Corbotec Meeting • Networking Receptions
TAPPI/AICC have announced the opening of registration for Corrugated Week 2022, taking place at the Henry B. González Convention Center in San Antonio, Texas. The Conference kicks off Monday, September 19, and offers exclusive show dates on September 20-21. The Grand Hy- att Hotel serves as the official host hotel. Corrugated Week 2022 features over 14 exclusive net- working events, giving you more opportunities to connect and grow your business: • Corrugated Week Classic Golf Tournament • Opening Night Reception • Networking Breakfasts
Take your corrugated vision to the next level with these cutting-edge program topics where you can learn from some of the industry’s top thought leaders: • Interactive Digital Printing Panel • Supply Chain Disruptions • How Can We Do More with Less? • Artificial Intelligence/Robotics/Automation • Emerging Leaders/Young Professionals Employee Re- cruitment/Retention As an added bonus, attendees can also register for the pre-conference course, “Effective Methods to Maximize Diecutting,” on Sunday, September 18.
• TAPPI Awards • AICC Awards
Visit corrugatedweek.org for general registration as well as pre-conference course registration and travel information. For infor- mation on exhibiting, contact Linda Cohen at (914) 544-0135 or lcohen@tappi.org. NAM: Consumer Spending Continues To Weaken Consumer spending has continued to weak- en in recent months, according to Chad Moutray, Ph.D. and Chief Economist at the National Association of Manufacturers (NAM). Monthly personal consumer expen- diture growth slowed to 0.2 percent in May (from 0.6 percent in April), as households’ income could not keep pace with inflation, and supply chain disruptions still limited the range of available products. Durable goods spending was the most affected (-3.2 per- cent). In real terms, consumer expenditures declined 0.4 percent in May. Consumers are concerned increasingly about inflation, particularly rising gas and food prices. These concerns have pushed the Conference Board Consumer Confi- dence Index further down in June from 103.2 to 98.7. Consumer expectations for the next six months tumbled to their lowest level since March 2013. Despite a decrease in the number of job openings for the second month in a row to 11.3 million in May (11.7 million in April), the job market remains very strong with the number of job openings per unemployed worker still close to historical highs at 1.9. The largest CONTINUED ON PAGE 8
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decreases occurred in professional and business ser- vices and in manufacturing while openings continued to increase in retail trade and leisure and hospitality. Hires and separations were largely unchanged. The strength of the labor market was confirmed by the June employment situation, which showed the U.S. econ- omy added 372,000 jobs in June, and unemployment re- mained stable at 3.6 percent. Shipments and new orders for manufactured durable goods remained strong in May (at +1.2 percent and +0.7 percent, respectively). Despite weaker consumer spend- ing, businesses continue to rebuild inventories. The June ISM Manufacturing PMI contracted to 53 per- cent from 56.1 percent in May, indicating that the expan- sion continues but at a slower pace. New orders dropped 5.9 percentage points to 49.2 percent, signaling that the inventory rebuilding may have run its course. The Semiconductor Industry Association released the latest World Semiconductor Trade Statistics monthly glob- al semiconductor sales numbers for May last Tuesday. While year-over-year monthly sales remained strong in May at 18 percent, they have decelerated throughout the year, indicating the semiconductor market is moving into a cyclical downturn. The question is to what degree will the macroeconomic headwinds described above weaken chip demand? NAM: Consumer Spending (CONT’D FROM PAGE 6)
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month March 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
37.675 37.992
-0.8
8.190 8.259
-0.8
Industry Total
Year-to Date
March 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
102.648 102.938
-0.3
8.019 8.170
-1.8
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2022 2021
3.1027 3.0967
0.2
8.4866 8.4625
0.3
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Mar. Feb.
2.2693 2.3081
-1.7
3.4 3.5
-2.9
Shipping Days
Year
Month
Year-to-Date
2022 2021
23 23
64 63
SOURCE: Fibre Box Association
Puhl custom designs systems to meet your needs. • Moving to a new facility? Puhl has experience moving entire plant systems all while minimizing down time in BOTH plants during the transition. • Below roof AND above roof systems custom designed to meet your needs. • New and Remanufactured Equipment (balers, blowers, separators, filters and more). Our Remanufactured equipment includes a warranty and offers significant savings. • NFPA and OSHA compliant systems designed by our NFPA trained engineering team. • Dust Briquetters, Certified Explosion Isolation Valves, Flame Front Diverters and more to control dust and meet NFPA requirements. • PLC Touch Screen Controls with Real Time Pressure Balancing and Real Time Remote Monitoring available on your smart phone or computer.
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ICG Names Clearwater Paper Its 2021 Supplier Of The Year
and excellent technical support. We are grateful for Clear- water Paper’s hard work to increase member sales.” Clearwater Paper is one of North America’s largest in- dependent producers of premium solid bleached sulfate (SBS) paperboard for quality-conscious printers and pack- aging converters.
The Independent Carton Group (ICG) has announced the presentation of its 2021 Supplier of the Year award to Clearwater Paper. The announcement was made at their quarterly meeting at Winston Packaging in Winston-Salem, North Carolina on March 17, 2022. The ICG and its members rate over 30 suppliers on a biannual basis on a series of criteria including: • Timeliness of delivery
• Quality of materials • Quality of service • Expertise of staff • Contractual compliance
• Administration / invoicing accuracy • Compliance with shipping instructions • Reporting and payments
Through the evaluation process ICG leadership works with national account managers from all their suppliers to improve the quality of service each supplier brings to ICG members. “The bottom line is to get best-in-class suppliers serving our members and that is what this awards program is helping to assure our members ofsaid Jay Willie, ICG Executive Director “Through this award, we want to rec- ognize Clearwater Paper for their exceptional paperboard product, superior service from both sales and production,
“We are immensely proud of our more than 20-year partnership with the ICG and its members,” said Clive Gil- landers, Director of Sales for Clearwater Paper’s Pulp and Paperboard Division. “Together, we have built a long-term relationship of trust and we look forward to continuing that relationship with the ICG for many years to come.” ICG Executive Director Jay Willie, right, presented the Supplier of the Year Award to Clive Gillanders of Clearwater Paper.
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PPC Celebrates Connection & Innovation At Inaugural PPC Week In Springfield, MA The paperboard Packaging Council (PPC) hosted a week filled with folding carton insights and education at its first PPC Week event at MGM Spring- field (MA) on June 6-10. PPC Week commenced with a record-breaking Folding Carton Boot Camp on June 6-7 and continued with Drupa in
Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals Paperless Workflows Mobile Sales Systems Digital Signage Production Monitoring Mobile Logistics Analytics & Reporting Cloud Hosting IT Management Services Cyber Security Management
Springfield from June 8-10. An unparalleled number of folding carton in- dustry newcomers attended PPC’s signature training program, with atten- dance to Bootcamp up by 120 percent from maximum attendees in previ- ous years. Approximately 70 professionals attended. Folding Carton Boot Camp, PPC’s signature “Carton 101 Training,” kicked off PPC Week by covering topics such as structural design and workflow, inks and coatings, laminating, digital diecutting, gluing and ad- hesives, rigid box, manufacturing and more. Instructors included key lead- Paperboard Packaging Council President Ben Markens, right, with happy grad- uates of the PPC’s Folding Carton Boot Camp.
600 + Plants 60,000 Users North America Latin America
ers within the folding carton industry who shared insights, developments, and technical information on each of their given topics. Hosted for the first time at MGM Springfield, attendees received hands-on learning opportu- nities on topics that span the full breadth of the folding carton industry. Boot Camp concluded with a graduation ceremony that celebrated grad- CONTINUED ON PAGE 14
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PPC Celebrates (CONT’D FROM PAGE 12)
of Tamarack Products. Inc.; Stu Lurie of Wilmington Paper; Jeff Bates of Leary, W.H.; George Folickman of Tilia Labs, Inc.; Carl Hirsch of Ink Systems Inc.; Chris Merendino of IMPACT Converting & Systems Solutions; and Chris Leary of Gietz-Vinfoil Americas. In addition to the case study presentations from mem- bers, PPC also invited thought leaders such as John Fraro, Director of Deli, Bakery and Food Service at Big Y World
uates for their desire to learn, understand, and grow both professionally and personally. The week continued with Drupa in Springfield, a dy- namic forum that showcased PPC Associate Members who shared the latest tools and technologies in the indus- try through comprehensive case studies. In total, 14 asso-
ciate members presented on key company learnings and insights, including Bill Rice of Heidelberg; Birgit Backofen Rothacker of ACTEGA North America; Eric Frank of Koenig & Bauer; Mark Hopkins of Komori America; Rob Bradshaw of Baumer hhs Corp.; John Pettus of Wikoff Color Corpora- tion; Doug Herr of Bobst North America, Inc.; Gayle Harrop Class Market, Dr. Steve Sobel, a renowned author, moti- vational speaker and educator, and Kevin Karstedt, Chief Executive Officer of Karstedt Partners, LLC, to speak on how their perspectives, experiences, and strategies have helped move their respective industries forward. CONTINUED ON PAGE 16 PPC Week included Drupa in Springfield, a forum that showcased PPC Associate Members who shared their technologies.
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Humility Patience Perseverance Fortitude...
... Just a few words that describe the amazing man we all knew and loved, Mike Lee. As an individual, Mike was someone who treasured the life that he was given. He was giving of his time and never shied away from those in need. He was steadfast in his principles and an inspiration to all. As a professional, he was a leader in the corrugated industry who conducted himself with integrity and respect for others. Customers loved him. Not only was he a master of his craft, but he was also an incredible mentor. Those of us at Haire Group and the industry who have learned from Mike are not naive to what an extraordinary opportunity it was. The legacy that Mike demonstrated to all customers and their machines will live on in spirit with every client interaction. We were all blessed to have known Mike. May God bless his family and all the lives he touched here on this earth.
IN MEMORY, WE HONOR ONE OF OUR OWN
OCTOBER 21, 1957 – JUNE 6, 2022 MIKE LEE
His legacy will live on forever through his team, his family, his friends, and every life he touched.
PPC Celebrates (CONT’D FROM PAGE 14)
Fraro shared the grocery retailer perspective in his key- note, reaffirming that collaboration through key strategic partnerships will pave the future for continued success in the industry. “Beyond labor, our packaging supply line is one of our largest spends, and it needs to keep evolving so we can expand offers,” Fraro said. He also posed the question to attendees: “What are your companies doing to not be transactional, but thoughtful, specific, and stra- tegic about your futures?” Fraro shared that Big Y is doing this by streamlining their offerings, stating, “Aggregation is going to be a huge path forward for both packaging and products.” Fraro also touched on the ideal qualities retailers are looking for in their packaging partners.“Social responsibili- ty, sustainability, and government advocacy are imperative for us to want to partner with you. Change is coming in the
packaging world, and we need to be strategically aligned in order to embrace it.” John Fraro, Director of Deli, Bakery and Food Service at Big Y World Class Market, shared the grocery retailer perspective.
Lastly, Fraro stated how important it is for packaging suppliers to present innovative products to retailers. “Unfortunately, the pan- demic stunted innovation – limiting our abil- ity to create meaningful partnerships within the industry. However, recently meeting with packaging manufacturers has been great for opening our communication channels to see what others are doing outside of our market.”
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PPC’s President, Ben Markens was thrilled with the outcome of the week-long celebra- tion of packaging innovation and growth say- ing, “Drupa in Springfield provided a unique opportunity for Associate Members to partner with carton converter members who use their products firsthand, all while showcasing the latest and greatest cutting-edge technology within the paperboard packaging industry. We’re looking forward to continuing to deep- en relationships, inspire connections, and pro- vide value for members at our Fall Meeting & Leadership Conference in Austin.” Registration is now open for PPC’s Fall Meeting & Leadership Conference at the Hy- att Regency in Austin, Texas, from October 26- 28, 2022. Visit paperbox.com for more.
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Brian Hunt Named President Of Southern Champion Tray
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Chattanooga, Tennessee based Southern Champion Tray LP (SCT) has announced the appointment of Brian Hunt
as President, effective July 1, 2022. Hunt follows John Zeiser, who has served as President since 1993 and recently celebrated 40 years with SCT, which has operations in Chat- tanooga; Mansfield, Texas; and Fair- field, Ohio. Zeiser will become Chair- man of the Board, and his brother,
Brian Hunt
Bruce Zeiser, will serve as Vice Chairman. “While our family will remain active and fully commit- ted to SCT, we are confident in Brian’s abilities to lead the company into its next chapter of growth,” said John Zeiser. “Brian is a proven leader who values people and has more than 30 years’ experience in the paperboard industry. His strong technical skills and industry expertise will be critical to guide our growth.” Hunt is the first non-family President of SCT and will be responsible for the overall strategic direction of the Com- pany, leading over 850 associates in continuing the com- pany’s 95 year track record of growth. He currently serves as Chairman of the Board of Directors of the Paperboard Packaging Council.
Nothing’s more rewarding than a couple made for each other. That’s why the engineers at ARC International have focused their skills and talents on
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ARC.5pAnlxChmb1BCN.CWk.indd 1
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Randy Banks Launches Job Board Specifically For Corrugated Industry Randy Banks of Sharp International has announced the creation of a job board specifically for the corrugated in- dustry at www.corrugated-jobboard.com . For the employer, the website is very intuitive, allows for a variety of reports, and features an interactive world map. A searchable database for resumes is currently in the works. For the job seeker, resume uploading (anonymous- ly, if desired) is free. Additional features include resume assistance, job alerts, applying for jobs with one click, and variety of reports. “Apart from being specifically for the corrugated in- dustry, what makes the job board unique is that we will be reaching out to qualified candidates every week,” said Banks. “The weekly e-mail will reach more than 7000 peo- ple in the corrugated industry, as well as other potential candidates, including those transitioning from the military and recent college graduates.” The month of July is free to post unlimited “Standard Job Posts.” “Premium Job Posts” and “Featured Job Posts” are offered at a 50 percent discount. Premium Job Posts will display at the top of the relevant keyword Job Search Results page. To register and to start posting jobs and reviewing available postings, visit corrugated-jobboard.com .
BCN(US)202109(o)(出血5mm).pdf 1 2021/9/7 下午 03:50:46
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Saica Pack (CONT’D FROM PAGE 1)
spaces with brightly painted walls, contemporary décor and large windows that provide natural lighting. The man- ufacturing area is clean, well-lit and features an ergonom- ic floorplan and the newest technology. The second floor provides access to an extensive mezzanine and catwalk that spans the entire perimeter of the production area, providing a bird’s eye view of the corrugator, paper roll storage, converting and gluing, finished goods storage and the intricate material handling system. When designing the plant floor layout and choosing equipment, Saica took a very European approach, install- ing highly automated machines and material handling components best suited for increased quality, shorter lead times - within one week - and fewer operators. “Finding people was a big challenge. But luckily we have very good technology in the plant so I don’t need as many people as
other companies because we have a lot of automation,” says Akin Burak Önder, General Manager. “This is a big ad- Saica Pack’s 360,000-square-foot greenfield plant is a model of efficiency and automation.
vantage. Automation is key. Our industry does not have the best profit margins. You need some balance and investments in automation and what we did here was a very correct de- cision.” The plant has a four-color Bobst FFG 1228NT RS and a four-color Bobst DRO 1628NT RS RDC with Speedstack and Speedpal, Bobst’s latest stacker and palletizer. The flexo folder-gluer has Valco Melton quality assurance systems for checking glue applications and gap and a Vistron Print Inspect system. Two additional print stations can be added to both machines if needed.
As part of the plant’s second phase, Saica will be adding a four-color Bobst FFG 820 and a two-color Bobst 1628 NT RS RDC, to be op- erational in the second half of 2023. The ma- chines will be mirrored with the ones already on the floor so the controls are easily accessed by one operator. The 110-inch (2.8m) Fosber corrugator is a 1375 FPM (420m) doublewall, double level 400 Series with Link M2 splicer/roll stand technol- The plant has a 50-inch 4-color Bobst FFG 1228NT RS and a 66-inch 4-color Bobst DRO 1628NT RS RDC.
CONTINUED ON PAGE 24
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Truck. Loads. More.
Corrugated printing has gone from basic to beautiful in 10 years. With the explosion of packaging demands and shorter print runs, speed has become the #1 capacity driver.
One of our customers tells us automated complete plate cleaning in < 4 minutes adds 25% capacity in a working week with FlexoCleanerBrush™
He calls it ‘Truckloads More Capacity’. You can do your own math.
Saica Pack (CONT’D FROM PAGE 22)
rolls in sequence and do a splice very quickly. Here we didn’t find the need.” Fosber’s Pro/Care and Pro/Quality systems monitor and provide data for the upkeep of the machine and in- spect the board for defects. Saica uses its own proprietary software for scheduling. While the intent is to run lighter weight basis weights, the corrugator is currently producing more conventional 32 and 44ECT. “Right now we are producing what our com- petitors are producing but as we get better established in the U.S. we will be producing our high performance recy- cled lightweight paper,” Aragüés says. First Vertical WIP Storage The WSA Material Handling System is fully automated from corrugator through the finished goods line and is con- trolled by WSA’s and KTC’s iFAS Smart Factory automation system, a PC based software package that is integrated with Saica’s ERP System and other OEM equipment which drives the sending and receiving of order information and other critical data used to track every load across the plant in real time. Sheets coming off the corrugator travel in one of three directions. 1. To a vertical WIP storage area (WSA’s and Warak’s first of its kind in North America); 2. To the finished goods line for strapping on two EAM Mosca strappers; or 3. To the converting machines. The decision to integrate a vertical WIP warehouse as CONTINUED ON PAGE 26
ogy and sound enclosures around the singlefacers. The M2 automatic roll stand splicer combination is suitable for longer runs for national account business. While many of Saica’s European facilities have Fos- ber’s M3 technology which allows the corrugator to run
at high speed even when running shorter orders, Aragüés explains that Saica is taking a different approach with the U.S. market. “We believe the orders are going to be sig- nificantly larger than in Europe. The M3 is beneficial when you have smaller orders because you can put the paper The 110-inch Fosber corrugator is a 1375 FPM doublewall, Dou- ble Level 400 Series with Link M2 splicer/roll stand technology.
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Saica Pack (CONT’D FROM PAGE 24)
outside the main factory building on a concrete slab. The rack is eight levels high, includes 384 cells, is serviced by two Korber Stacker Cranes and can store approximately 10,000,000-square-feet of product, which includes both primary and secondary WIP. The total power requirements for the system with two stacker cranes is 180 amps. “For comparison purposes, a traditional WIP system for a fac- tory of this size would occupy a space of 40,000-square- feet yet would only be able to accommodate 5,000,000 square-feet of product and would require over 500 amps of power,” McLaughlin says. WSA also provided a fully automatic Tooling Delivery System that delivers tooling carts including ink, printing plates and cutting dies to and from the mezzanine to each converting line and waste carts from the converting ma- chines to the baler room. This will be integrated with a new SERRA Fully Automatic Die and Printing Plate Rack system in July. The material transport and vertical WIP offers many benefits, Önder says. “We are not touching the box. In terms of quality and service there is no bottleneck for run- nability so you can run the corrugator 24 hours and store sheets and you’re not touching the sheets so the perfor- mance and the quality will be much better.” Aragüés says, “We are able to separate the customer’s fluctuations on the converting machines from the corruga- tor because we have such a big buffer between the cor-
opposed to traditional floor conveyor was considered from the very beginning as this solution has been well proven in recent years in Europe, according to Jim McLaughlin, President of WSA-USA LLC. It offers significant benefits in optimizing storage capacity, reducing building size and cost, minimizing energy consumption, lessening product
handling, and maximizing plant efficiencies in how product is scheduled and run on the corrugator. The vertical WIP warehouse at Saica Pack Hamilton has a footprint of 11,000-square-feet and is positioned WSA and Warak’s Vertical WIP Storage System is the first of its kind in North America.
CONTINUED ON PAGE 28
We’ve got our customers covered… …with our fiberglass backed, boltless, full double-wide blankets and an extensive inventory of corrugated parts needed by virtually every box plant in the country. The innovator of the original fiberglass-backed knuckle locking anvil cover, Stafford is the industry’s go-to source for everything corrugated. TM
www.go2stafford.com 800-282-5787 IS THE MANUFACTURER OF STAFFORD ANVIL COVERS ®
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Saica Pack (CONT’D FROM PAGE 26)
rugator and the converting machines that we are able to optimize production on the corrugator and we’re able to produce very long runs because we have this huge stor- age capacity between corrugating and converting.”
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“It gives us better lead times and quality,” Önder adds. “That is our competitive advantage when we say perfor- mance packaging with quality and service in terms of of- fering to the market paper, product, and innovative solu- tions.” Market Differentiation Saica’s key differentiator for the U.S. market is going to be its lightweight packaging and different flute com- binations, such as P-flute which is not a common flute in the U.S. “We are an expert in producing lightweight paper and high performance packaging that compares to higher grade packaging from other competitors,” Aragüés says. Initially, the plan was to import paper to the U.S. from Saica’s European paper mills, however, supply chain is- sues torpedoed that strategy. “If we want to do things dif- ferently, we need to have our paper, but right now trying to bring our paper from Europe is pretty crazy because of the freight rate, so we are buying the paper from local suppli- ers,” he says. “As soon as the supply chain constraints that we are suffering globally ease a little bit, we will be import- ing more of our papers and then have a paper mill here.” About five years ago, Saica’s European plants began producing high quality flexo printing — up to seven and eight colors — on white coated brown recycled paper. This is something the company is planning to introduce to The rack of WSA and Warak’s Vertical WIP Storage System is eight levels high and includes 384 cells.
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CONTINUED ON PAGE 30
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It’s time to revolutionize The new CorruCUT rotary die-cutter pushes what is possible
The CorruCUT is designed for high-performance rotary production of die-cut corrugated products with ultimate flexo post-printing quality. You will achieve paramount performance from the latest embedded technology with a brand new operating concept. It is available with the industry's shortest lead time from our factory to your floor. The CorruCUT has a maximum production output of 12,000 boards per hour, including setup while running, integrated remote maintenance for the ultimate uptime, and the easiest machine to operate – the CorruCUT will increase your profitability. Call us to set up a custom demonstration. Koenig & Bauer (+1) 502 310-1368 tom.fitzgerald@koenig-bauer.com koenig-bauer.com
Saica Pack (CONT’D FROM PAGE 28)
educational content and tabletop exhibits aimed to assist startup manufacturing companies grow their operations. This new program is for founders and leaders of startup manufacturing companies looking to scale their brand to larger production through either in-house facility build out or outsourced relationships with contract manufacturers and packagers. Exhibitors will include suppliers of pack- aging machinery, packaging materials, processing equip- ment, and contract manufacturing and packaging ser- vices. The agenda and speakers will be announced soon. Attendees can sign up for event updates and be notified as speakers are added. Event content is specifically designed for: • Companies evaluating in-house and outsourced manu- facturing and packaging solutions • Founders of high-growth emerging brands looking to scale operations • Leaders of product development, operations, or fi- nance The Emerging Brands Summit will take place in tandem with the PACK EXPO International trade show. Registration for the Emerging Brands Summit is within the PACK EXPO International registration site. By purchasing a registration for the Emerging Brands Summit, attendees will automati- cally receive a complimentary registration for PACK EXPO International and can attend all four days of the trade show Visit emergingbrandssummit.com to learn more and to register for the event.
the U.S. market. Indeed, the strategy in the U.S. is to pro- vide distinctive products, such as white coated paper and high-end printing. Ideal markets for these products include beverage and FMCG customers for national and global companies, such as P&G, Unilever, Amazon, Nestle, and Diageo, many of which Saica already has a relationship with in Europe. “We are targeting to have those customers here, but they want us to be bigger here,” Aragüés says. Saica is planning to build three more plants and a pa- per mill in the U.S.; a second facility has already been an- nounced for Ohio or Indiana. “With the four box plants, we think that one of them will be very close to the paper mill.” Aragüés says Saica’s strength in the U.S. market is ser- vice, quality and high performance packaging. “Because of our high automation, we are able to offer better service and because of our quality inspection systems we are able to offer better quality.” Emerging Brands Summit To Launch At PACK EXPO International The brand-new Emerging Brands Summit, produced by PMMI Media Group, will launch at PACK EXPO Internation- al 2022, taking place from October 23-26 at McCormick Place in Chicago, Illinois. This one-day event will feature
Do you need printed sheets? We have your answer.. Introducing Heartland’s ColorCorr. This is “flexo-printing in the round”. On our corrugator we can print up to 109” wide. The advantage is that we can print the equivalent of ½ roll at a time and not be required to keep several rolls of very expensive preprinted paper on the floor. Much less waste and risk. In continual print mode, we use either laser-engraved rubber rolls or solid rubber rolls to print a “flood coat” or a repeating pattern. If we are printing a repeating pattern, we can run a two-color design on the paper. Customers have found that running sheets we print can allow them to run a lighter-grade due to reduced caliper loss, and in some cases eliminate one or more machine passes.
For more information contact: Charlie Freeman | 816-500-8889 | cfreeman@heartlandsheets.com Tim Kramer | 816-841-8317 | color@heartlandsheets.com
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International PaperBox To Invest In Koenig & Bauer Rapida Press At International PaperBox, the accent is on quality and customization. Serving a variety of businesses in the Utah and Mountain West vicinity, this nearly 20-year-old folding carton packaging printer has gained a committed custom- er base that seek unique and difficult jobs incorporating printing, folding, and gluing applications. To continue to provide high quality service and quality, the firm decided to boost its production and capacity with a new Koenig & Bauer Rapida 106 seven-color UV press. “We’re stepping up our game,” says International Pa- perBox CEO Wade Holbrook, who owns the 50-employee business along with his wife Kay. “There’s no comparison between our current 15-year-old 40-inch press and our new Rapida 106 press in terms of speed and automation.
Our customers and our firm will be benefiting from its ef- ficiency, giving us at least 50 percent more capacity if not Kay and Wade Holbrook, owners of International PaperBox, visited Koenig & Bauer’s German factory to see their new Rap- ida 106 seven-color press being built.
more. Its digital quality control features will be new to our press crew, providing an improved focus on production excellence.” Working with his Koenig & Bauer sales rep- resentative, Holbrook specifically chose fea- tures that would enhance his firm’s reputation for quality and customization. An important- new feature is the Koenig & Bauer QualiTronic PDFCheck, which provides International Pa- perBox with sheet inspection and comparison of the printed sheet with a PDF. Its operators will be alerted to differences to the PDF and then once approved it switches over to in- spection to inspect every sheet over the run length. Due to its variety of packaging work, the firm added the board package to enhance substrate versatility and board thicknesses with a substrate range up to 48pt. The Rapida 106 is specified as a raised press to run larger loads to keep up with the higher speeds and multiple pile changes. The new Rapida 106 brings automation and ultra-fresh features that didn’t exist more than a decade ago. Press crews at International PaperBox will gain ink density measurement and control utilizing the Rapida’s QualiTronic ColorControl feature. Its camera system takes automatic measurements of every sheet via optical density on the sheet’s color bar, which serve as a basis for inline control of the ink key settings. Armed with a custom Koenig & Bauer VariDRY UV system, the Rapida press operators will see jobs quickly print and dry as they move to postpress finishing. Holbrook is pleased that his 21-year-old lead pressman can’t wait to get his hands on the new Rapida with all of its high-tech automation and will go to Germany for additional training.
Once recycled, corrugated box fibers are used 7-10 times to make new boxes and other paper products. And, more corrugated packaging is recovered for recycling than any other packaging material. Corrugated attracts eco-conscious customers who prefer to choose sustainably packaged products. Environmentally Responsible. Recyclable. Compostable. Extraordinary.
Learn more at boxesareextraordinary.com
CONTINUED ON PAGE 34
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